Bale shape monitor for round balers

ABSTRACT

A round baler includes a bale shape monitor for facilitating uniform bale formation. The bale shape monitor includes a pair of end sensors and an intermediate sensor. The end sensors sense the diameter of the bale at end locations adjacent opposite ends of the bale, while the intermediate sensor senses the diameter of the bale at an intermediate location spaced between the end locations. The monitor further includes a signal responsive to the sensors to indicate to the operator when the diameter of the bale at one of the end locations is less than the diameter at the intermediate location. The signal is electrically powered and includes a pair of switches, each of which is operably coupled between one of the end sensors and the intermediate sensor to operate an indicator when the diameter of the bale sensed at the corresponding end location is less than the diameter sensed at the intermediate location.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to round balers and, moreparticularly, to an improved bale shape monitor for facilitating uniformbale formation by the baler.

2. Discussion of Prior Art

In most instances, the crop windrow picked up by a round baler tends tobe narrower than the overall length of the baling chamber. The balermust consequently be steered left and right as it pulled across thefield so that an equal amount of crop material is delivered along thelength of the chamber during the bale cycle; otherwise, the baler willlikely form an asymmetrical bale having an uneven diameter from one endto end the other end. For example, if the baler is positioned relativeto the windrow so that a disproportionate amount of crop is delivered tothe left end of the baling chamber, the bale will almost definitely havea conical shape, with the left end of the bale having a greater diameterand density than the right end. In any case, nonuniform bale formationresults in unsightly bales that are difficult to sell, stack and tie.Moreover, nonuniform bale formation often damages or, at the very least,places undue wear on the bale forming components.

Even the most skillful baler operator has difficultly in tediouslyweaving the baler from side to side for ensuring even delivery of cropmaterial between the sidewalls of the baler. Accordingly, bale shapemonitors have been developed to assist the operator with uniform baleformation. Conventional bale shape monitors typically include indicatorsplaced within the cab of the tractor to signal to the operator when thebale is not being properly shaped. Traditional indicators include baleshape displays which represent the shape of the bale from end-to-end orat certain locations along the length of the bale. A more commonindicator includes so-called "driving lights" which signal to theoperator when to steer left, steer right or simply drive forward.Additionally, some balers have even been equipped with a steeringmechanism for automatically steering the baler left and right inresponse to the bale shape sensed by the monitor.

The indicators mentioned above are traditionally operated by one or moresensors on the baler. In round balers having an expandable balingchamber defined in part by a plurality of endless elements (e.g., abelt-type baler), the sensors are associated with the endless elementsadjacent the sidewalls of the baler. Each end sensor is often positionedalong a stretch of the corresponding element to detect when the stretchbecomes slackened. It will be appreciated that the elements aretraditionally tensioned by a single slack takeup mechanism, andaccordingly, slackening of one of the elements relative to the remainingelements indicates that the area of the baling chamber bound by the oneelement is receiving less crop material than the others. Alternatively,the ends sensors are positioned along stretches of the elements definingthe baling chamber so as to directly sense the diameter of the bale. Theoperator may consequently steer the baler left or right depending uponthe diameter of the bale sensed adjacent the ends thereof.

However, these known expedients are problematic. Particularly,conventional bale shape monitors have complex and relatively expensiveconstructions. Additionally, a number of conventional monitors are notdependable and do not accurately sense the shape of the bale. Forexample, with monitors having a sensor for detecting the slack conditionof one of the endless elements, the shape of the bale may not beaccurately detected because of uneven stretching between the elements.Moreover, no baler has heretofore been provided with a monitor whicheffectively compares the diameter of the bale adjacent the ends thereofto the diameter of the bale at an intermediate location spaced betweenthe ends, so that the operator is signaled when the ends are deficientrelative to the middle of the bale. As will subsequently be described,this significantly simplifies the construction of the monitor and moreaccurately detects bale shape to improve uniform bale formation.

OBJECTS AND SUMMARY OF THE INVENTION

Responsive to these and other problems, an important object of thepresent invention is to provide a round baler with an improved baleshape monitor for facilitating uniform bale formation. Another importantobject of the present invention is to provide a bale shape monitor thatis more dependable yet less expensive and complex in construction thanconventional monitors. More particularly, an important object of thepresent invention is to provide a bale shape monitor that effectivelycompares the diameter of the bale adjacent the ends thereof to thediameter adjacent the middle of the bale. Yet another important objectof the present invention is to provide such a bale shape monitor whichsignals to the operator when the diameter adjacent one of the ends ofthe bale is less than the diameter at the middle of the bale.

In accordance with these and other objects evident from the followingdescription of a preferred embodiment of the invention, the round balerincludes a pair of end sensors and an intermediate sensor. The endsensors sense the diameter of the bale at end locations adjacentopposite ends of the bale, while the intermediate sensor senses thediameter of the bale at an intermediate location spaced between the endlocations. The monitor further includes a signal responsive to thesensors to indicate to the operator when the diameter of the bale at oneof the end locations is less than the diameter at the intermediatelocation.

It has been determined that the middle of the bale (i.e., the portion ofthe bale spaced substantially equally between the sidewalls of thebaler) rarely has less density or a smaller diameter than both ends ofthe bale. As the baler is weaved along the windrow, crop material isessentially continuously delivered to the middle of the baling chamber.This is due to the fact that the incoming crop material will naturallypropagate to the middle of the baling chamber. Furthermore, because ofthe width of traditional windrows, crop material is virtually constantlydelivered to the middle of the baling chamber, even when the windrow isintentionally picked up along one side of the baler. Accordingly, it ishighly unlikely that the middle of the bale will be deficient relativeto both ends of the bale, as long as the baler is weaved along thewindrow. In other words, there is little risk of a bale having aso-called "hourglass shape".

The present invention is specifically designed to prevent the morelikely situation of the bale having a so-called "egg or football shape",wherein the ends of the bale have less density and a smaller diameterthan the middle of the bale. The claimed bale shape monitor essentiallycompares the diameter of the bale sensed by the end sensors to thediameter of the bale sensed by the intermediate sensor, and signals theoperator when the former is less than the latter. As will be apparentfrom the following description, the inventive bale shape monitor isrelatively more dependable, yet more simple and inexpensive inconstruction, than conventional devices.

Other aspects and advantages of the present invention will be apparentfrom the following detailed description of the preferred embodiment andthe accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

A preferred embodiment of the invention is described in detail belowwith reference to the attached drawing figures, wherein:

FIG. 1 is a fragmentary, side elevational view of a round baler with theleft sidewall and various other parts being removed to illustrateinternal details of construction including the bale shape monitorconstructed in accordance with the principles of the present invention,with the baler containing a full-size bale;

FIG. 2 is a fragmentary, side elevational view of the round balersimilar to FIG. 1, but illustrating the bale forming components in theirinitial start-up configuration (i.e., with the baling chamber empty);

FIG. 3 is an enlarged, fragmentary, horizontal sectional view lookingdownwardly at the front half of the baler, particularly illustrating thelocation of the end sensors and the intermediate sensor between thesidewalls of the baler;

FIG. 4 is an enlarged, fragmentary, horizontal sectional view of theupper end of the right retainer arm and a portion of the bale shapemonitor, particularly illustrating the structure for mounting thesensors to the arm;

FIG. 5 is an enlarged, fragmentary side elevational view of the rightretainer arm and a portion of the bale shape monitor, particularlyillustrating the position of the right end sensor and the condition ofthe signal when the diameter adjacent the right end of the bale issubstantially similar to the diameter at the middle of the bale;

FIG. 6 is an enlarged, fragmentary side elevational view similar to FIG.5, but illustrating the position of the right end sensor and thecondition of the signal when the diameter adjacent the right end of thebale is less than the diameter at the middle of the bale;

FIG. 7 is an enlarged, side elevational view of the right end sensor andthe portion of the signal associated therewith;

FIG. 8 is an enlarged, side elevational view of the left end sensor andother parts of the bale shape monitor;

FIG. 9 is an enlarged, top plan view of the parts of the bale shapemonitor which are mounted to the baler;

FIG. 10 is schematic view of the bale shape monitor, particularlyillustrating the condition of the monitor when the bale has a generallyuniform diameter from end to end;

FIG. 11 is a schematic view of the bale shape monitor similar to FIG.10, but illustrating the condition of the monitor when the diameter ofthe bale adjacent its left end is less than the diameter at the middleof the bale; and

FIG. 12 is a schematic view of the bale shape monitor similar to FIG.10, but illustrating the condition of the monitor when the diameter ofthe bale adjacent its right end is less than the diameter at the middleof the bale.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning initially to FIG. 1, the round baler 10 selected forillustration generally includes a chassis or frame 12 that is supportedfor travel by a pair of ground wheels 14 (only the right ground wheelbeing shown in the drawings figures). A tongue 16 projects forwardlyfrom the chassis 12 for connection with a towing vehicle (not shown).The chassis 12 carries a pair of upright, laterally spaced sidewalls 18and 20 (see also FIG. 3) which cooperate to define a space within whichbale forming and bale wrapping operations may be carried out as thebaler is advanced across a field. A pair of left and right frame members22 and 24 extend upwardly from the chassis 12 to assist with supportingthe sidewalls 18 and 20 in their upright disposition.

In the present embodiment, the baler 10 includes a number of rolls andbelts that cooperate with the sidewalls 18,20 to define an internalbaling chamber 25 that assumes different shapes and sizes throughout thebale-forming cycle. Particularly, the baler 10 has a plurality oflaterally extending, stationary rolls including a rear drive roll 26, afront drive roll 28, and a plurality of idler rolls30,32,34,36,38,40,42,44,46. The stationary rolls 26-46 are arrangedbetween the sidewalls in a generally circular pattern (when viewingFIGS. 1 and 2) for guiding a plurality of laterally spaced, endlessbelts 48, as the belts are driven linearly during bale formation andwrapping. As perhaps best shown in FIG. 3, the illustrated baler 10includes six of the belts 48. The rear drive roll 26 and the idler roll46 are located generally at the bottom of the baling chamber 25 and arespaced apart in a generally fore-and-aft direction to define anon-compressive, chamber inlet opening 50 therebetween. As the balegrows progressively larger, the idler roll 44 eventually cooperates withthe idler roll 46 to define the rear boundary of the inlet opening 50,for purposes which will subsequently be described. The belts 48 arelooped under the rear drive roll 26, under the tailgate-mounted idlerroll 46, and over the large upper idler roll 38 so that the beltspresent a pair of generally upright belt stretches 52 and 54 when thebaling chamber 25 is empty at the beginning of a bale-forming cycle (seeFIG. 2).

The bale forming mechanism further includes a belt guiding or retainingassembly 56 having a pair of vertically swingable arms 58 and 60 locatedinside the baler adjacent the sidewalls 18 and 20. The arms 58,60support two idler rolls 62 and 64 in a position to directly overlie thebale during its formation within the chamber 25. Further, the arms 58,60are yieldably biased downwardly so that the rolls 62,64 exert pressureagainst the top of the bale as it is formed. The rolls 62 and 64 arespaced apart by a distance which is much less than the width of theinlet opening 50, and the vertical belt stretches 52 and 54 are confinedbetween the rolls 62 and 64 in such a manner that the belt stretches52,54 converge toward one another as the rolls 62,64 are approached.Since the rolls 62,64 are essentially directly above the inlet opening50, the rolls 62,64 cause the chamber 25 to assume a generally vertical,triangular configuration when the chamber 25 is empty and the arms 58,60are in their lowermost position as shown in FIG. 2. With the drive rolls26 and 28 rotating in a clockwise direction as depicted in FIGS. 1 and2, the front belt stretch 52 moves in a downward direction, while therear belt stretch 54 moves in an upward direction, when the chamber 25is empty at the beginning of a new bale forming cycle. A slack controlarm assembly 66 located in the upper front portion of the baler 10includes a pair of vertically swingable arms 68 (only one being shown)that support idler rolls 70 and 72. As those of ordinary skill in theart will appreciate, the assembly 66 controls the amount of slack paidout to the belts 48 as the bale grows within the chamber 25.

The baling chamber 25 is obviously located well above and off theground. Therefore, some means must be provided for picking up cropmaterial as the baler moves across the field and for delivering thepicked-up material into the chamber 25. In the illustrated embodiment,the baler 10 is constructed in accordance with the principles of openthroat, vertical chamber baling, such that the incoming crop material isnot to be subjected to any significant compression until it passesthrough the inlet opening 50 and is fully received within the balingchamber 25. Thus, that part of the crop flow path upstream from thechamber 25 is open and non-compressive and may be described as an openthroat 74 through which the picked-up crop material passes on its way tothe baling chamber 25.

In the illustrated embodiment, the crop material is picked up off theground by a standard resilient rotary rake tine assembly 76 locatedbelow and forwardly of the chamber 25 and its inlet opening 50. Theassembly 76 is positioned along the lower portion of the throat 74 andcooperates with the rear drive roller 26 in helping to define the throat74. The resilient rake tines 78 of the assembly 76 describe a somewhatcircular path of travel as shown in phantom lines in FIGS. 1 and 2,although the tines 78 actually are cam-operated and are caused toretract along the rear stretch of their path of travel.

If the rake tine assembly 76 selected for use is wider than the chamber25 in a direction transverse to the path of travel of the machine, thepicked-up material must be converged toward the center of the baler 10by center-gathering stub augers 80 (only one being shown in FIGS. 1 and2) or the like before being delivered into the chamber 25. One suitablestub auger construction for accomplishing this function is disclosed inco-pending application Ser. No. 08/731,764, filed Oct. 18, 1996 andtitled "Down Turning Stub Augers on Wide Pick-Up for Round Balers". Ifthe rake tine assembly 76 is the same width as the chamber 25, acenter-gathering mechanism is not needed.

A rigid tooth feeder 82 is positioned below and in vertical alignmentwith the inlet opening 50 between the resilient rake tine assembly 76and the lower idler roll 46 along the lower stretch of the throat 74.The feeder 82 is spaced below the rear drive roll 26 and helps to definethe throat 74. In the preferred embodiment, the feeder 82 takes the formof a fork 84 having a series of transversely spaced, rigid teeth 86 thatmove in a generally kidney-shaped path of travel illustrated in phantomlines in FIGS. 1 and 2. The teeth 86 project into the throat 74 during astuffing stroke along the upper half of their path of travel and retractdown out of the throat 74 during a return stroke along the lower half oftheir path of travel. A slotted ramp 88 spanning the distance betweenthe resilient tine assembly 76 and the lower idler roll 46 provides afloor for the throat 74 in the vicinity of the rigid tooth feeder 82 andserves as a stripper plate through which the teeth 86 may retract torelease the crop material at the rear end of the path of travel of theteeth 86.

The fork 84 is pivotally supported by a rotating carrier 90 that rotatescontinuously about a transverse horizontal axis 92. The fork 84 isconnected near its mid-point to the carrier 90 and has its lowerextended end pivotally connected to a control link 94 pivotally coupledwith the chassis 12. Thus, although the carrier 90 rotates in a circularpath of travel, the fork 84 is constrained to move in its kidney-shapepath of travel as illustrated. As shown in FIGS. 1 and 2, the idlerrolls 46 and 44 cooperate with the ramp 88 when the bale in chamber 25grows larger than a starting core to define an eased path along whichincoming crop material travels as it enters the chamber 25 as disclosedin co-pending application Ser. No. 08/731,395, filed Oct. 18, 1996, andtitled "Eased Inlet Tailgate Roll Arrangement for Variable Chamber RoundBaler". This configuration of the inlet opening 50 provides anaggressive nip between the belts 50 and the bale to facilitate theaddition of crop material to the bale during the bale-forming cycle.

Contrary to prior open throat, vertical chamber constructions, the baler10 has no starter roll located in the chamber 25 behind the rear driveroll 26. However, also contrary to prior open throat vertical chamberconstructions, the baler 10 has the rigid tooth feeder 82 disposed belowthe open bottom of the chamber 25 in vertical alignment with the inletopening 50. Consequently, the rigid tooth feeder 82 is positioned forprojecting crop materials into the chamber 25 during successive stuffingstrokes, whether such materials comprise only incoming materialsreceived from the resilient tine assembly 76 or also materials that mayhave fallen down out of the chamber 25 during the early stages of balecore starting. The no starter roll construction of the illustrated baler10 is the subject of copending application Ser. No. 08/896,720, filedJul. 18, 1997, and titled "Vertical Chamber, Open Throat Round BalerHaving No Starter Roll".

In the illustrated embodiment, the resilient rake tine assembly 76 ismounted on the chassis 12 for up and down swinging movement about atransverse axis 96 (FIGS. 1 and 2) which coincides with the axis ofrotation of the stub augers 80. Gauge wheels 99 (only the right wheelbeing shown) secured to the resilient rake tine assembly 76 by inverted,generally U-shaped arms 98 (only a portion of one of the arms beingshown in FIGS. 1 and 2) ride along the ground to cause the resilienttine assembly 76 to swing up or down as necessary to accommodate changesin ground contour. It will be noted that in the illustrated embodiment,the stub augers 80 and the rigid tooth feeder 82 do not pivot with theresilient tine assembly 76 but are instead mounted in fixed positions onthe chassis 12. However, it is within the scope of the present inventionto have all three of the components comprising the rake tine assembly76, the rigid tooth feeder 82 and the stub augers 80 constructed as partof a header unit swingably attached to the chassis 12. In theillustrated embodiment, the gauge wheels 99 are attached to theresilient tine assembly 76 in the manner disclosed and claimed inco-pending application Ser. No. 08/733,758, filed Oct. 18, 1996, andtitled "Over-the-top Support Arm for Pick-up Gauge Wheel of a Baler".

As shown in FIGS. 1 and 2, the baler 10 is provided with a standardwindguard 100 overlying the resilient rake tine assembly 76. Thewindguard 100 is pivoted to the chassis 12 at pivot 102 and is biased bygravity to lie against the wrapper 104 of the resilient tine assembly 76and the ramp 88 associated with the rigid tooth feeder 82. As incomingcrop material flows through the throat 74, the windguard 100 is raisedoff the wrapper 104 and the ramp 88 by the moving crop material.However, the windguard 100 provides no significant compaction of thecrop material.

As illustrated in FIGS. 1 and 2, power for operating the components ofthe baler is delivered by a driveline 106 associated with the tongue 16.The front end of the driveline 106 is adapted for connection to thepower take-off shaft (not shown) of the towing vehicle, while the rearend of the driveline 106 is coupled with the input shaft 108 of a rightangle gear box 110 on a transverse structural member 112 of the chassis12. The output shaft 114 of the right angle gear box 110 is coupled inthe usual manner with the various drives for the baler components.

When the bale is fully formed within the chamber 25 as illustrated bythe bale 116 in solid lines in FIG. 1, it may be wrapped by a suitablewrapper before being discharged from the baler. In the illustratedembodiment, a twine dispenser 118 is located adjacent the front of thebaler above the windguard 100 for wrapping the finished bale with twineduring the wrapping cycle of the machine. Once wrapped, the bale may bedischarged from the baler by operating a pair of lift cylinders (notshown) on opposite sides of the machine to elevate the rear half of thesidewalls 18,20 and the rolls 40,42,44,46 supported thereon. The rearhalf of the machine thus functions as a tailgate that is attached to thefront half and pivots relative thereto about an upper pivot 120 at thetop of the baler 10.

BALE SHAPE MONITOR

During the bale-forming cycle, the rotary rake tine assembly 76, stubaugers 80 and the tooth feeder 82 cooperatively deliver material pickedup from a crop windrow (not shown) to the baling chamber 25. Generallyspeaking, with a few exceptions (e.g., the crop material picked upoutboard of the sidewalls 18,20 and converged centrally by the stubaugers 80), the crop material is delivered to the baling chamber 25 atgenerally the same lateral location relative to the sidewalls 18,20 atwhich the windrow was picked up off the ground by the rotary rake tineassembly 76. For example, when the baler 10 is positioned relative tothe windrow so that crop material is picked up by the center portion ofthe rotary rake tine assembly 76, the crop material is in turn deliveredgenerally to the middle of the baling chamber 25. Because most cropwindrows are traditionally narrower than the length of the balingchamber 25, the baler 10 must be skillfully weaved from side to side forensuring even delivery of crop material between the sidewalls 18 and 20;otherwise the bale will likely have a nonuniform shape, with thediameter of the bale varying from end to end. This is tedious andtiresome for even the most experienced bale operators.

Accordingly, the baler 10 is provided with an improved bale shapemonitor 122 for facilitating uniform bale formation. The illustratedmonitor 122 effectively compares the diameter of the bale adjacent itsends to the diameter at the middle of the bale, and signals the operatorwhen the one of the end diameters is less than the middle diameter. Aswill be apparent from the following description, the monitor 122, whichis constructed in accordance with the principles of the presentinvention, has a relatively simple and inexpensive, yet dependableconstruction.

As perhaps best shown in FIG. 3, the monitor 122 includes a pair of endsensors 124 and 126 for sensing the diameter of the bale adjacent thesidewalls 18 and 20. It may be said that each of the sensors 124 or 126senses the bale diameter at an end location adjacent one of the ends ofthe bale. The monitor 122 further includes an intermediate sensor 128spaced substantially equally between the end sensors 124,126 for sensingthe diameter at the middle of the bale. The intermediate sensor 128senses the bale diameter at an intermediate location spaced between theend locations. In this respect, the monitor 122 is provided with meansfor sensing the bale diameter at three locations spaced along the lengthof the bale. The bale diameter sensed at each end location iscontinuously gauged relative to the bale diameter sensed at theintermediate location so that the operator is notified whenever one ofthe end locations has a smaller diameter than the intermediate location,as will be further described. This construction is particularlyeffective in assisting the operator with weaving of the baler 10 alongthe windrow so as to avoid the formation of bales having an egg orfootball shape.

In the illustrated embodiment, the intermediate sensor 128 is in theform of a shiftable diameter gauge associated with one of the centermostbelts of the baler 10. Particularly, the intermediate sensor or gauge128 includes an arm 130 swingably mounted to the baler 10, and a feelerwheel 132 mounted to one end of the arm 130 by a nut-and-bolt assembly134 (see FIG. 3). A bearing assembly (not shown) contained within thewheel 132 serves to journal the latter on the nut-and-bolt assembly 134for relative rotational movement. The wheel 132 is preferably formed ofa rubber material, although other suitable materials, such as plastic ormetal, may be used.

The location of the intermediate sensor 128 is such that the wheel 132rides against the front stretch 52 of the third belt spaced from theleft sidewall 18. As perhaps best shown in FIG. 3, the wheel 132 islocated substantially equally from the sides of the belt so as to reducethe risk of disengagement therebetween should there be any problems withbelt tracking. Those of ordinary skill in the art will appreciate thatthe location of the wheel 132 along the backside of the front stretch 52ensures that the diameter at the middle of the bale is positively sensedby the intermediate sensor 128. That is to say, the wheel 132 engagesone of the belt stretches 52 defining the baling chamber 25 so that thelocation of the wheel 132 directly corresponds to the diameter of thebale. The intermediate sensor 128 may alternatively be located adjacentthe rear of the baling chamber 25, with the wheel 132 engaging one ofthe centermost belts along the rear stretch 54 thereof, if desired. Itis also noted that the term "middle" as used herein shall be interpretedto mean a location spaced generally equally between the ends of thebale. With respect to the illustrated embodiment, the diameter of themiddle of the bale is sensed even though the wheel 132 for theintermediate sensor 128 is spaced slightly leftward of the center of thebaler. Of course, the principles of the present invention are equallyapplicable to a baler having an odd number of belts (e.g., seven belts)so that the wheel for the intermediate sensor is closer to the center ofthe baling chamber than depicted in the drawing figures. In fact, such aconstruction may allow the intermediate location to be spaced virtuallyequally from the sidewalls (i.e., from the ends of the bale).

A cylindrically shaped, transverse bar 136 is provided for swingablysupporting the arm 130 of the intermediate sensor 128 on the baler 10.As shown in FIGS. 3 and 4, the arm 130 is fixed to the bar 136 bysuitable means, such as welding, at a position laterally aligned withone of the centermost belts. Adjacent opposite ends of the bar 136 arebearing supports 138 and 140 for rotatably supporting the bar 136 on thebelt retaining arms 58 and 60. As shown in FIG. 4, the right bearingsupport 140 comprises a sleeve 142 rotatably receiving the right end ofthe bar 136, and a support plate 144 projecting from the sleeve 142. Apair of nut-and-bolt assemblies 146 serve to fasten the support plate144 to a bracket 148 fixed to the right retaining arm 60 adjacent therolls 62 and 64. The left bearing support 138 is similar in constructionto the right bearing support 140 and therefore will not be described indetail. It is sufficient to explain that the left bearing support issimilarly fastened by a pair of nut-and-bolt assemblies 150 to a bracket152 projecting inwardly from the left retaining arm 58 (see FIGS. 3 and9). A pair of holes 154 provided in the right bracket 148 for receivingthe nut-and-bolt assemblies 146 have an elliptical shape to accommodatefor manufacturing errors, etc. The left bracket 152 is likewise providedwith elliptically shaped holes 156.

The intermediate sensor 128 is consequently mounted on the retainingarms 58 and 60 for swinging movement therewith. This convenientconstruction maintains the proximity between the baling chamber 25 andthe support structure for the intermediate sensor 128 so as to reducethe size and cost of the intermediate sensor.

The wheel 132 of the intermediate sensor 128 is yieldably biased againstthe corresponding belt by a pair of tension springs 158 and 160 locatedadjacent opposite ends of the bar 136. As perhaps best shown in FIG. 3,the left spring 158 is connected between a tab 162 fixed to the leftretaining arm 58 to project inwardly therefrom and a crank 64 projectingfrom the left end of the bar 136. It will be noted that the tab 162 andcrank 64 each include a small hole for removably receiving therespective hook-shaped end of the spring 158. The right spring 160 islikewise associated with a tab 162 fixed to the right retaining arm 60and a crank 164 fixed to the right end of the bar 136. In this respect,the springs 158 and 160 cooperate to yieldably urge the bar 136, andthereby the arm 130, in a direction that causes the wheel 132 to bepressed against the front stretch 52 of the corresponding belt formaintaining contact therebetween in virtually all chamber conditions.Because the location of the arm 130 and wheel 132 constantly coincidewith the shape of the bale underlying the corresponding belt, theintermediate sensor 128 continuously senses the bale diameter at themiddle of the bale.

Each of the end sensors 124 and 126 is also in the form of a shiftablebale diameter gauge. Furthermore, the end sensors 124 and 126 similarlyengage the front stretch 52 of the belts, but do so along the endmostbelts of the baler 10. Because of these similarities, it will beappreciated that the same caveats and alternatives noted above withrespect to the intermediate sensor 128 likewise apply to the end sensors124 and 126.

The left end sensor 124 includes a swingable arm 170 and a rotatablewheel 172 mounted adjacent one end of the arm 170 by a nut-and-boltassembly 174. The wheel 172 is journaled on the nut-and-bolt assembly174 for relative rotational movement by a bearing assembly (not shown)contained within the wheel 172. As shown in FIG. 8, the arm 170 isprovided with an elongated hole 176 for receiving the nut-and-boltassembly 174, for purposes which will subsequently be described. Fixedto the opposite end of the arm 170 is a cylindrical collar 178 forsupporting the arm 170 on the bar 136. The collar 178 loosely receivesthe bar 136 so as to allow relative movement therebetween. However, aswill further be described hereinbelow, swinging movement of the arm 170relative to the bar 136 is limited so that the springs 158 and 160 alsoserve to yieldably urge the arm 170 in a clockwise direction (viewingFIG. 8) for causing the wheel 172 to be yieldably pressed against thefront stretch 52 of the leftmost belt. Additionally, the location of thecollar 178 along the length of the bar 136 is similarly maintained sothat the wheel 172 presses against the leftmost belt at a point spacedequally between the sides of the belt.

The right end sensor 126 is structurally and functionally similar to theleft end sensor 124, and it is therefore sufficient to explain that theright end sensor 126 includes a swingable arm 180 and a rotatable wheel182 mounted to one end of the arm 180 by a nut-and-bolt assembly 184. Asshown with phantom lines in FIG. 7, the arm 180 includes an elongatedhole 186 for receiving the nut-and-bolt assembly, which facilitatescalibration of the monitor 122 as will subsequently be described. Acollar 188 fixed to the opposite end of the arm 180 and received on thebar 136, as perhaps best shown in FIG. 4, serves to swingably supportthe arm 188 on the bar 136. The wheel 182 of the right sensor 126yieldably presses against the front stretch 52 of the rightmost belt ata point spaced equally between the sides of the belt (see FIG. 3).

In view of the foregoing, the position of the arm 170 and wheel 172 ofthe left end sensor 124 directly corresponds with the location of theleftmost belt as it moves responsive to bale growth, so that the leftend sensor 124 senses the diameter of the bale underlying the leftmostbelt (i.e., the diameter adjacent the left end of the bale). Similarly,the position of the arm 180 and wheel 182 of the right end sensor 126directly corresponds with the location of the rightmost belt so that theright end sensor 126 senses the diameter of the bale underlying therightmost belt (i.e., the diameter adjacent the right end of the bale).It will be appreciated that the end sensors 124 and 126 are notnecessarily limited to being associated with the endmost belts of thebaler 10; that is, in some baler constructions, it may be sufficient toassociate the end sensors with a belt that is only proximate to theadjacent baler sidewall. For example, the bale diameter may besufficiently detected by associating the end sensors 124 and 126 with abelt spaced inwardly from one or more of the other belts. Furthermore,it is entirely within the ambit of the present invention to utilize apair of end sensors and an intermediate sensor with other variouslyconstructed endless elements (e.g., chains) that cooperate with thebaler sidewalls to define the baling chamber.

The illustrated bale shape monitor 122 further includes a signalgenerally referenced by the numeral 190 in FIGS. 10-12. The signal 190is responsive to the sensors 124,126,128 for indicating when one of theend sensors 124 or 126 detects a bale diameter that is less than thebale diameter sensed by the intermediate sensor 128. As will be apparentfrom the following description, the signal 190 cooperates with thesensors 124,126,128 to effectively compare the diameter at each endlocation to the diameter at the intermediate location and signal theoperator when the former is less than the latter.

The signal 190 includes a pair of switches 192 and 194, one of which(switch 192) is associated with the left end sensor 124 and the other ofwhich (switch 194) is associated with the right end sensor 126 (see FIG.3). In the illustrated embodiment, the switches 192 and 194 comprisestandard normally open, ball-type switches, although the principles ofthe present invention are equally applicable to various other switchconstructions, such as normally closed switches. In any case, activationof the switch shall be interpreted to mean that the state of the switchhas been changed (e.g., if the switch is normally open as depicted inthe illustrated embodiment, activation of the switch involves closingthe switch so that the circuit path is completed). As will subsequentlybe described, the left switch 192 is operably coupled between the leftend sensor 124 and the intermediate sensor 128 in such a manner that theswitch 192 is activated as the sensors 124 and 128 shift relative to oneanother when the bale diameter adjacent the left end of the bale is lessthan the bale diameter at the middle of the bale. The right switch 194is similarly coupled between the right end sensor 126 and theintermediate sensor 128 to be activated when the left end of the balehas a smaller diameter than the middle of the bale.

As perhaps best shown in FIG. 3, the left switch 192 is supported on aplate 196 projecting from the collar 178 so that the switch 192 swingswith the arm 170 of the left end sensor 124. A somewhat trapezoidalshaped switch activating member 198 is fixed to the bar 136 so thatswinging of the member 198 corresponds with swinging of the arm 130 ofthe intermediate sensor 128. As shown in FIG. 3, the support plate 196for the switch 192 and the activating member 198 are partiallysuperimposed. Accordingly, if the support plate 196 swings sufficientlydownwardly as a result of the diameter adjacent the left end of the balebeing less than the diameter at the middle of the bale, the ball orcontact 200 (see FIGS. 10-12) of the left switch 192 engages the member198 to thereby activate the switch 192. As shown in FIGS. 10-12, theswitch 192 is connected to a power source by a lead 202 and to anindicator 206 by a lead 208. Accordingly, when the activating member 198contacts the ball 200, the circuit path between the power source and theindicator 206 is completed, and the indicator 206 is thereby operated.

Similar to the left switch 192, a support plate 208 serves to similarlyfix the right switch 194 relative to the right arm 180 so that theswitch 194 and the arm 180 swing together, as perhaps best shown in FIG.7. A switch activating member 210 projecting from the bar 136 isconfigured to engage the ball or contact 212 of the switch 194, when thebale diameter adjacent the right end of the bale is less than thediameter at the middle of the bale. A lead 214 connects the right switch194 with a power source, which may be the same power source connected tothe left switch 192, and a second lead 216 connects the switch to anindicator 218, whereby the indicator 218 is operated when the switch 194is activated.

Connected between the support plate 208 and the switch activating member210 is a spring biasing mechanism 220. As perhaps best shown in FIG. 7,the mechanism 220 includes a nut-and-bolt assembly 222 and a compressionspring 224 for yieldably biasing the support plate 208 toward the switchactivating member 210. It will be noted that the illustrated compressionspring 224 is retained between the nut of the assembly 222 and thesupport plate 208, although the spring may alternatively be retainedbetween the bolt head and the switch activating member 210. In anyevent, the mechanism 220 serves to limit swinging movement of thesupport plate 208 relative to the activating member 210. In other words,swinging of the support plate 208 (and the right arm 170) in a clockwisedirection (when viewing FIG. 7) is limited relative to the switchactivating member 210 by the compressibility of the spring 224 and thelength of the nut-and-bolt assembly 222. Because the activating member210 is yieldably biased in a counterclockwise direction by the springs158,160, the support plate 208 and the right arm 180 are also biased inthat same direction so that the wheel 182 yieldably presses against therightmost belt. Furthermore, with the activating member 210 being fixedrelative to the arm 130 of the intermediate sensor 128, swingingmovement of the right arm 180 is also limited relative to the positionof the intermediate arm 130. It is also noted that the compressionspring 224 assists the springs 158 and 160 in causing the wheel 182 ofthe right end sensor 126 to be yieldably pressed against the rightmostbelt. In addition, the spring 224 ensures contact between the ball 212of the switch 194 and the activating member 210 when the diameteradjacent the right end of the bale is less than the diameter at themiddle of the bale. With the support plate 208 being fixed to the rightarm 180 and the switch activating member 210 being fixed to the bar 136,the mechanism 220 also serves to maintain the location of the right endsensor 126 along the bar 136.

Because swinging movement of the right arm 180 relative to theintermediate arm 130 is limited, there may be instances in which thewheel 182 of the right end sensor 126 disengages the rightmost belt.This may occur because the diameter adjacent the right end of the baleis severely deficient relative to the diameter at the middle of thebale, whereby the right end arm 180 is swung completely toward thebaling chamber relative to the intermediate arm 130. It will beappreciated that such swinging of the right end arm 180 relative to theintermediate arm 130 is limited by the interengagement between theswitch 194 and the activating member 210. Accordingly, even in thissituation, the right end sensor 126 continues to "sense" the balediameter adjacent the right end of the bale as being less than thediameter at the middle of the bale.

Although not shown in detail, a similar spring biasing mechanism 226 isconnected between the support plate 196 and the activating member 198associated with the left end sensor 124 (see FIG. 3). The mechanism 226is structurally and functionally similar to the mechanism 220 associatedwith the right end sensor 126. For the sake of brevity, the mechanism226 will not be described in detail.

As indicated above, the arms 170 and 180 of the end sensors 124 and 126are provided with elongated holes 176 and 186, respectively, whichallows the operator to calibrate the bale shape monitor 122. The arm 130of the intermediate sensor 128 is likewise provided with an elongatedhole (not shown) which facilitates such calibration. It will beappreciated that calibration of the monitor 122 may be required as aresult of manufacturing inaccuracies, uneven belt stretching, etc.

In the illustrated embodiment, the nut-and-bolt assembly 174 of the leftend sensor 124 is located at the bottom of the hole 176 (see FIG. 8),and the nut-and-bolt assembly 184 of the right end sensor 126 issimilarly located at the bottom of the hole 186 (see FIG. 7). Althoughnot illustrated, it will be appreciated that the nut-and-bolt assembly134 of the intermediate sensor 128 is located at the top of the slottedhole. This configuration ensures that there is a gap between theswitches 192 and 194 and the switch activating members 198 and 210,respectively, when the diameter of the bale at the corresponding endlocation is substantially similar to the bale diameter at the middle ofthe bale. That is to say, this configuration reduces the likelihood ofinadvertent operation of the indicators so as to further facilitateuniform bale formation. However, if for some reason calibration isrequired or an asymmetrical bale is desired, the nut-and-bolt assembliesmay be shifted within the respective holes so as to vary the position ofthe wheel relative to the arm. For example, the nut-and-bolt assemblies174 and 184 of the end sensors 124 and 126 may be shifted to the top ofthe holes 176 and 186, respectively, to promote formation of a balehaving an hourglass shape.

The indicators 204 and 218, which are illustrated schematically in FIGS.10-12, preferably comprise so-called "driving lights". In this respect,the indicators 204 and 218 are illuminated to alert the operator whenthe diameter adjacent the corresponding end of the bale is less than thediameter at the middle of the bale. The indicators 204 and 218 may bearranged side-by-side on a display panel (not shown), with the positionof the indicators 204 and 218 corresponding to the location of theirrespective switches 192 and 194, so that the operator quickly associatesillumination of one of the indicators with a deficiency along thecorresponding end of the bale. For example, if the diameter of the baleadjacent the left end is less than the diameter of the middle of thebale, the left indicator 204 is illuminated. On the other hand, theposition of the indicators 204 and 218 on the display panel may bereversed, and the indicators may be provided with indicia for signalingthe operator to steer the baler in a direction which would cause morecrop material to be delivered to the deficient end. For example, theindicator 204 associated with the left switch 192 may include thewording "steer right", so that the operated is alerted to steer thebaler 10 righwardly for delivering relatively more crop material to theleft side of the baling chamber 25. Preferably, the display panelsupporting the indicators 204 and 218 is located within the cab of thetowing vehicle (not shown). Moreover, the principles of the presentinvention are applicable to various other indicator constructions. Forexample, the indicators 204 and 218 may comprise an audible signal, suchas a speaking sound stating "steer left" or "steer right", if desired.In addition, the monitor may include a third indicator (not shown) whichis coupled to the switches 192 and 194 for signaling the operator todrive forward when both switches are not activated.

At the start of the bale-forming cycle, all of the sensors 124,126,128are in a position best exemplified by the location of the right endsensor 126 depicted in FIG. 2. As crop material is progressively addedto the baling chamber 25, the belt stretches 52 and 54 move away fromone another in a generally circular manner, and the retaining arms 58and 60 swing upwardly and carry with them the sensors 124,126,128.However, the sensors 124,126,128 maintain contact with the respectivebelts for sensing the diameter of the bale underlying the belt. The baleforming components and the sensors 124,126,128 will eventually bedisposed in the manner depicted in FIG. 1, which corresponds with auniformly shaped, fully formed bale 116. If one of the ends of the balehas a diameter less than the diameter of the middle of the bale at anytime between the start and finish of the bale-forming cycle, the balemonitor 122 will alert the operator of this condition so that thenecessary corrections may be made.

For example, when the bale diameter adjacent the right end of the baleis substantially equal to the bale diameter at the middle of the bale,the switch 194 associated with the right end sensor 126 will not beactivated, as depicted in FIGS. 5 and 10-11. However, if the balediameter adjacent the right end of the bale is less than the balediameter at the middle of the bale, the arm 180 of the right end sensor126 will swing toward the baling chamber 25, while the arm 130 of theintermediate sensor 128 remains relatively stationary. This relativemovement causes the right switch 194, which is fixed relative to theright arm 180, to engage the switch activating member 210, which isfixed relative to the intermediate arm 130, so as to activate the switch194 and thereby operate the indicator 218 (see FIGS. 6 and 12). Ineffect, the bale diameter adjacent the right end of the bale is comparedto the diameter at the middle of bale by the monitor 122, and theoperator is alerted when this comparison reveals that the diameter atthe end location is less than the diameter at the intermediate location.As depicted in FIG. 11, the monitor 122 is similarly configured to alertthe operator when the diameter adjacent the left end of the bale isrelatively less than the diameter at the middle of the bale.

The preferred forms of the invention described above are to be used asillustration only, and should not be utilized in a limiting sense ininterpreting the scope of the present invention. Obvious modificationsto the exemplary embodiments, as hereinabove set forth, could be readilymade by those skilled in the art without departing from the spirit ofthe present invention. For example, the bale shape monitor 122 may beutilized as a retrofit attachment for existing round balers. It will beappreciated that FIG. 9 conveniently illustrates the components of themonitor 122 which are attached to the baler.

The inventors hereby state their intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as pertains to any apparatus not materially departingfrom but outside the literal scope of the invention as set forth in thefollowing claims.

What is claimed is:
 1. In a round baler including an expandable balingchamber which increases in size as a cylindrical bale is formed therein,a bale shape monitor comprising:an end diameter sensor for sensing thediameter of the bale at an end location adjacent one of the ends of thebale; an intermediate diameter sensor for sensing the diameter of thebale at an intermediate location spaced laterally inwardly from the endlocation; and a signal responsive to the diameter sensors to indicatewhen the diameter at the end location is less than the diameter at theintermediate location.
 2. In a round baler as claimed in claim 1; andasecond end diameter sensor for sensing the diameter of the bale at asecond end location adjacent the end of the bale opposite from the firstmentioned end location, said intermediate location being spaced betweenthe end locations, said signal being further responsive to the secondend and intermediate diameter sensors to indicate when the diameter atthe second end location is less than the diameter at the intermediatelocation.
 3. In a round baler as claimed in claim 2,each of saiddiameter sensors including a shiftable bale diameter gauge which shiftsas the bale diameter changes.
 4. In a round baler as claimed in claim3,said gauge comprising a swingable arm and a roller rotatably supportedadjacent one end of the arm to be positioned against the baling chamber.5. In a round baler as claimed in claim 4,said gauge including biasingmechanism coupled with the arm for yieldably biasing the roller towardthe baling chamber.
 6. In a round baler as claimed in claim 3,saidsignal including a pair of indicators, each of which is associated withone of the end diameter sensors for signaling when the diameter of thebale at a corresponding one of the end locations is less than thediameter at the intermediate location.
 7. In a round baler as claimed inclaim 6,said indicators being operable independently of one another. 8.In a round baler as claimed in claim 7,said signal being electricallypowered and including an electrical circuit having a pair of switches,each of said switches being associated with one of the end diametersensors to operate a respective one of the indicators when the diameterof the bale at the corresponding end location is less than the diameterat the intermediate location.
 9. In a round baler as claimed in claim8,each of said indicators comprising a light.
 10. In a round baler asclaimed in claim 8,said gauge of each of the end diameter sensorscooperating with the gauge of the intermediate diameter sensor topresent a pair of corresponding gauges which are operably coupled with arespective one of the switches for activating said respective one of theswitches as the gauges shift relative to one another when the balediameter at the corresponding end location is less than the diameter atthe intermediate location.
 11. In a round baler as claimed in claim10,said respective one of the switches being fixed relative to one ofthe gauges of the corresponding pair, and including a contact whichserves to activate the switch when engaged, said signal including aswitch activating member fixed relative to the other of the gauges ofthe corresponding pair for engaging the contact as the gauges shiftrelative to one another when the bale diameter at the corresponding endlocation is less than the diameter at the intermediate location.
 12. Ina round baler including a plurality of laterally spaced endless elementsdisposed between a pair of sidewalls for cooperatively defining anexpandable baling chamber which increases in size as a cylindrical baleis formed therein, a bale shape monitor comprising:a pair of enddiameter sensors associated with respective ones of the elements tosense the diameter of the bale at end locations adjacent opposite endsof the bale; an intermediate diameter sensor associated with one of theelements spaced between said respective ones of the elements to sensethe diameter of the bale at an intermediate location spaced between theend locations; and a signal responsive to the diameter sensors toindicate when the diameter of the bale at one of the end locations isless than the diameter at the intermediate location.
 13. In a roundbaler as claimed in claim 12,each of said diameter sensors including ashiftable bale diameter gauge associated with a respective one of theelements, with the gauge being shifted as the bale diameter changes atthe respective one of the elements.
 14. In a round baler as claimed inclaim 13,said gauge comprising a swingable arm and a roller rotatablysupported adjacent one end of the arm, said roller being engageable withthe respective one of the elements.
 15. In a round baler as claimed inclaim 14,said gauge including biasing mechanism coupled with the arm foryieldably biasing the roller against the respective one of the elements.16. In a round baler as claimed in claim 13,said signal including a pairof indicators, each of which is associated with one of the end diametersensors for signaling when the diameter of the bale at a correspondingone of the end locations is less than the diameter at the intermediatelocation.
 17. In a round baler as claimed in claim 16,said indicatorsbeing operable independently of one another.
 18. In a round baler asclaimed in claim 17,said signal being electrically powered and includingan electrical circuit having a pair of switches, each of said switchesbeing associated with one of the end diameter sensors to operate arespective one of the indicators when the diameter of the bale at thecorresponding end location is less than the diameter at the intermediatelocation.
 19. In a round baler as claimed in claim 18,each of saidindicators comprising a light.
 20. In a round baler as claimed in claim18,said gauge of each of the end diameter sensors cooperating with thegauge of the intermediate diameter sensor to present a pair ofcorresponding gauges which are operably coupled with a respective one ofthe switches for activating said respective one of the switches as thegauges shift relative to one another when the bale diameter at thecorresponding end location is less than the diameter at the intermediatelocation.
 21. In a round baler as claimed in claim 20,said respectiveone of the switches being fixed relative to one of the gauges of thecorresponding pair, and including a contact which serves to activate theswitch when engaged, said signal including a switch activating memberfixed relative to the other of the gauges of the corresponding pair forengaging the contact as the gauges shift relative to one another whenthe bale diameter at the corresponding end location is less than thediameter at the intermediate location.
 22. A bale shape monitor forattachment to a round baler including a plurality of laterally spacedendless elements disposed between a pair of sidewalls for cooperativelydefining an expandable baling chamber which increases in size as acylindrical bale is formed therein, said monitor comprising:a pair ofend diameter sensors and an intermediate diameter sensor; supportstructure for mounting the diameter sensors on the baler so that the enddiameter sensors sense the diameter of the bale at end locationsadjacent opposite ends of the bale and the intermediate diameter sensorsenses the diameter of the bale at an intermediate location spacedbetween the end locations; and a signal responsive to the diametersensors to indicate when the diameter of the bale at one of the endlocations is less than the diameter at the intermediate location.
 23. Abale shape monitor as claimed in claim 22,each of said diameter sensorsincluding a bale diameter gauge associated with a respective one of theelements, said support structure serving to shiftably mount the gauge onthe baler so that the gauge shifts as the bale diameter changes at therespective one of the elements.
 24. A bale shape monitor as claimed inclaim 23,said gauge comprising a swingable arm and a roller rotatablysupported adjacent one end of the arm, said roller being engageable withthe respective one of the elements.
 25. A bale shape monitor as claimedin claim 24,said gauge including biasing mechanism coupled with the armfor yieldably biasing the roller against the respective one of theelements.
 26. A bale shape monitor as claimed in claim 23,said signalincluding a pair of indicators, each of which is associated with one ofthe end diameter sensors for signaling when the diameter of the bale ata corresponding one of the end locations is less than the diameter atthe intermediate location.
 27. A bale shape monitor as claimed in claim26,said indicators being operable independently of one another.
 28. Abale shape monitor as claimed in claim 27,said signal being electricallypowered and including an electrical circuit having a pair of switches,each of said switches being associated with one of the end diametersensors to operate a respective one of the indicators when the diameterof the bale at the corresponding end location is less than the diameterat the intermediate location.
 29. A bale shape monitor as claimed inclaim 28,each of said indicators comprising a light.
 30. A bale shapemonitor as claimed in claim 28,said gauge of each of the end diametersensors cooperating with the gauge of the intermediate diameter sensorto present a pair of corresponding gauges which are operably coupledwith a respective one of the switches for activating said respective oneof the switches as the gauges shift relative to one another when thebale diameter at the corresponding end location is less than thediameter at the intermediate location.
 31. A bale shape monitor asclaimed in claim 30,said respective one of the switches being fixedrelative to one of the gauges of the corresponding pair, and including acontact which serves to activate the switch when engaged, said signalincluding a switch activating member fixed relative to the other of thegauges of the corresponding pair for engaging the contact as the gaugesshift relative to one another when the bale diameter at thecorresponding end location is less than the diameter at the intermediatelocation.